Methods of creating soft and lofty nonwoven webs

ABSTRACT

A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing two molten polymer components having different melting temperatures to a spinneret defining a plurality of orifices, and flowing a fluid intermediate the spinneret and a moving porous member. The moving porous member is positioned below the spinneret. The method includes using the fluid to draw or push the two molten polymer components, in a direction that is toward the moving porous member, through at least some of the plurality of orifices to form a plurality of individual bi-component continuous fiber strands. The method includes depositing the continuous fiber strands on the moving porous member at a first location to create an intermediate continuous fiber nonwoven web, and removing and/or diverting some of the fluid proximate to the first location to maintain loft and softness in the deposited intermediate continuous fiber nonwoven web.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, Patent Application No. PCT CN2018/118638, filed on Nov.30, 2018, the entire disclosure of which is hereby incorporated byreference.

FIELD

The present disclosure is generally directed to methods of creating softand lofty fiber nonwoven webs, and, is more particularly directed to,methods of creating soft and lofty continuous fiber nonwoven webs.

BACKGROUND

Nonwoven webs may comprise continuous fibers. The continuous fibers maybe manufactured by a continuous fiber nonwoven manufacturing operationto form a continuous fiber nonwoven web. In such an operation,continuous fiber strands of molten polymer may be drawn or pusheddownwardly from a spinneret by a fluid, such as air, toward a movingporous member, such as a moving porous belt. During the drawing orpushing, the continuous fiber strands may be quenched and stretched. Thefluid (i.e., process air) flows toward the moving porous member. In someinstances, vacuum may be applied under the moving porous member to aidin drawing the continuous fiber strands and the fluid toward the movingporous member. After the continuous fiber strands contact the movingporous member, the fluid may travel downstream with the newly formed webof continuous fiber strands and typically has to be removed by applyingvacuum under the moving porous member. This vacuum reduces the loft ofthe continuous fiber strands on the moving porous member and inhibitsthe continuous fibers from crimping during cooling. Conventionalspunbond processes also use a compaction roller proximate to a contactpoint between the continuous fiber strands and the moving porous member.The compaction roller reduces the loft on the newly formed web andinhibits fiber crimping. Conventional spunbond processes also usecalendering to place bonds in the web, which substantially reduces theloft. Further, a hot air knife may be used in place of the compactionroller to pre-bond the web and fully seal a surface of the web. The hotair knife reduces cooling of the web, and thereby reduces crimping ofthe continuous fibers since crimping occurs during cooling. The hot airknife further reduces air permeability of the web, which is not desired.The fluid removal through the moving porous member, the compactionroller, the calendering, or the hot air knife may fully lock or bond thenewly formed continuous fiber web and prevent, or at least inhibit,fibers from crimping on the moving porous member. This significantlyreduces loft and softness of the newly formed web of continuous fibersand is not desired for some nonwoven applications, such as softnonwovens for absorbent articles. As such, continuous fiber nonwovenmanufacturing operations should be improved to create nonwoven webs withimproved loft and softness, especially in the context of a continuousfiber nonwoven web that is through-fluid bonded.

SUMMARY

The present disclosure solves the problems of reduced loft, reducedsoftness, and reduced fiber crimping of the continuous fiber nonwovenwebs. One important aspect is to allow the continuous fibers enoughtime, in a non-compacted or non-fully bonded state, on the moving porousmember to remain lofty and have sufficient strength to be transported tosubsequent process steps, such as another fiber laydown (i.e., anadditional beam) or bonding. The present inventors have developedsystems to reduce fiber compaction and surface sealing, therebyincreasing loft and softness in a nonwoven web. As one example, thefluid (i.e., process air) may be removed or diverted from a firstlocation to protect the web from stagnant air proximate to where thecontinuous fiber strands initially contact the moving porous member.This allows for reduced vacuum being applied through the moving porousmember as the newly formed web travels downstream of the first location,thereby promoting increased loft, softness, and fiber crimping. If thefluid is removed (compared to merely being diverted) from proximate tothe first location, it may be blown-off, or may be used in thepre-bonding step as discussed below. A compaction roller or a hot airknife may not be used to prevent, or at least inhibit, smashing(compaction roller) and fully sealing (hot air knife) of the continuousfibers. In some instances, a compaction roller applying a very lightcompaction force may be used while still achieving fiber crimping.

If a compaction roller is not used, or even if a very light compactionroller is used, one issue that may arise is fiber blow-back on themoving porous member. That is, fibers falling back on themselves (in adirection opposite a machine direction) because the fibers are notbonded together to form a web with suitable integrity for processing.The present inventors propose a few solutions to fiber blow-back thatmay or may not be used in combination. First, the continuous fiberstrands on the moving porous member may be pre-bonded with a hot fluid,such as hot air, infrared technology, or other technology, in less than100%, less than 75%, less than 50%, less than 25%, or less than 10%, forexample, of a side of the continuous fiber web. The pre-bonding occurson the side of the continuous fiber web facing away from the movingporous member. The hot fluid may be at least some of the same fluidremoved proximate to the first location, but that has been heated. Inother instances, the hot fluid may be separately supplied to theprocess. In any event, the hot fluid may be used to pre-bond thecontinuous fiber web on the moving porous member downstream of the firstlocation. This hot fluid may be at a much lower pressure compared to thepressure applied by a compaction roller, thereby leading to lesscompaction of the unbonded web. Some examples of pre-bonding using thehot fluid may use a perforated drum (that may or may not also remove thehot process fluid) or a perforated plate. Using a perforated member willallow pre-bonding to occur in less than 100% of the surface of thecontinuous fiber web, thereby allowing better air permeability, lesscompaction between pre-bonded areas, and allowing the fibers to stillcrimp on the moving porous member. The perforated member also allowspre-bonding to occur intermittently in the machine direction and/or thecross machine direction. Second, a fluid diverter may be used above themoving porous member to at least inhibit stagnant air from contactingthe web. The web may be placed in between the moving porous member andthe fluid diverter to prevent, or at least inhibit, fiber blow back. Theweb may be in contact with both the fluid diverter and the moving porousmember therefore having increased shear force to enable transportationunder a lower web strain. As crimping may still continue, the machinedirection strain of the web may be reduced to a negative number or avery low web strain, thereby allowing the fibers to curl to promotebetter loft. The fluid diverter may be an elongated plate or anelongated conveyor belt, for example. The fluid diverter may act toshield the web from stagnant process air. Third, water steam or otherliquid may be sprayed on the web proximate to, but downstream of, thefirst location to reduce fiber blow-back. The water or other liquid willstill allow the fibers to crimp, but will allow them to be conveyed onthe moving porous member at speed with reduced fiber blow-back. Further,the water or other liquid will be evaporated in a through-fluid bondingprocess downstream of the water or other liquid application point.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of example forms of the disclosure taken inconjunction with the accompanying drawings, wherein:

FIG. 1 is a diagrammatic view of an apparatus for performing a processfor forming a through-fluid bonded continuous fiber nonwoven webincluding pre-bonding and reorienting and/or relofting of the continuousfibers;

FIG. 2 is a diagrammatic view of an apparatus for performing a processfor forming a through-fluid bonded continuous fiber nonwoven webillustrating a fluid handing roll and an elongated fluid diversionelement;

FIG. 3 is a plan view of a portion of a process illustration of FIG. 2showing an example elongated fluid diversion element positioned over themoving porous member;

FIG. 4 is a plan view of a portion of the process illustration of FIG. 2showing another example elongated fluid diversion element positionedover the moving porous member and with a liquid being applied to theintermediate continuous fiber nonwoven web;

FIG. 5 is a plan view of a portion of a process illustration showing anexample elongated fluid diversion element positioned over the movingporous member;

FIG. 6 is a plan view of a portion of a process illustration showing aprocess fluid remover/diverter and an elongated fluid diversion element;

FIG. 7 is a plan view of a portion of the process illustration of FIG. 2showing an example fluid handling roll and an elongated fluid diversionelement;

FIG. 8 is a plan view of a portion of the process illustration of FIG. 2showing an example fluid handling roll and an elongated fluid diversionelement;

FIG. 9 is a plan view of the process fluid diverter or remover of FIGS.7 and 8;

FIG. 10 is a top view of a portion of an intermediate continuous fibernonwoven web comprising a plurality of pre-bonds;

FIG. 11 is a plan view of a pre-bonding apparatus used to form pre-bondsin an intermediate continuous fiber nonwoven web;

FIG. 12 is a bottom view of an example of the pre-bonding apparatus ofFIG. 11 in the form of a perforated plate; and

FIG. 13 is a cross-sectional view of the perforated plate of FIG. 12,taken about line 9-9 of FIG. 8.

DETAILED DESCRIPTION

Various non-limiting forms of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the methods of soft andlofty nonwoven webs disclosed herein. One or more examples of thesenon-limiting forms are illustrated in the accompanying drawings. Thoseof ordinary skill in the art will understand that the methods ofcreating soft and lofty nonwoven webs described herein and illustratedin the accompanying drawings are non-limiting example forms and that thescope of the various non-limiting forms of the present disclosure aredefined solely by the claims. The features illustrated or described inconnection with one non-limiting form may be combined with the featuresof other non-limiting forms. Such modifications and variations areintended to be included within the scope of the present disclosure.

Nonwoven Webs

Nonwoven webs are useful in many industries, such as the hygieneindustry, the dusting and cleaning implement industry, and thehealthcare industry, for example. In the hygiene industry, nonwoven websare used in the absorbent article field, such as use as components indiapers, pants, adult incontinence products, tampons, sanitary napkins,absorbent pads, bed pads, wipes, and various other products. Nonwovenwebs may be used in diapers, pants, adult incontinence products, and/orsanitary napkins, for example, as topsheets, outer cover nonwovenmaterials, portions of leg cuffs, acquisition materials, core wrapmaterials, portions of ears and side panels, portions of fastener tabs,and/or secondary topsheets, for example. The nonwoven webs of thepresent disclosure are not limited to any certain industry orapplication, but can have application across many industries orapplications.

Fiber Composition

The fibers of the nonwoven webs of the present disclosure may comprisemulti-constituent fibers, such as bicomponent fibers or tri-componentfibers, for example, mono-component fibers, and/or other fiber types.Multi-constituent fibers, as used herein, means fibers comprising morethan one chemical species or material (i.e., multi-component fibers).Bicomponent fibers are used in the present disclosure merely as anexample of multi-constituent fibers. The fibers may have round,triangular, tri-lobal, or otherwise shaped cross-sections, for example.It may be desirable to have fibers comprising more than one polymercomponent, such as bicomponent fibers. Often, these two polymercomponents have different melting temperatures, viscosities, glasstransition temperatures, and/or crystallization rates. As themulti-component fibers cool after formation, a first polymer componentmay solidify and/or shrink at a faster rate than a second polymercomponent while the second polymer component may have sufficientrigidity to resist compression along a longitudinal fiber axis. Thecontinuous fibers may then deform and curl up when strain on the fiberis relieved, and thereby causing what is known as “crimp” in the fibers.Crimp of the fibers aids in the softness and loft of a nonwoven web,which is consumer desirable. Examples of bicomponent fibers may comprisea first polymer component having a first melting temperature and asecond polymer component having a second melting temperature. The firstmelting temperature of the first polymer component may be about 5degrees C. to about 180 degrees C., about 10 degrees C. to about 180degrees C., or about 30 degrees C. to about 150 degrees C., differentthan the second melting temperature of the second polymer component,thereby causing crimping of the fibers during cooling, specificallyreciting all 0.1 degree C. increments within the specified ranges andall ranges formed therein or thereby. The first and second meltingtemperatures may differ by at least 5 degrees, at least 10 degrees C.,at least 20 degrees, at least 25 degrees, at least 40 degrees C., atleast 50 degrees C., at least 75 degrees C., at least 100 degrees C., atleast 125 degrees C., at least 150 degrees C., but all less than 180degrees C., for example. As a further example, a first polymer componentmay comprise polypropylene and a second polymer component may comprisepolyethylene. As yet another example, a first polymer component maycomprise polyethylene and a second polymer component may comprisepolyethylene terephthalate. As yet another example, a first polymercomponent may comprise polyethylene and a second polymer component maycomprise polylactic acid. If tri-component fibers are used, at least onepolymer component may have a different melting temperature (in theranges specified above) than a melting temperature of at least one ofthe other two polymer components. The fibers may comprise petroleumsourced resins, recycled resins, and/or or bio-sourced resins, such aspolylactic acid from Nature Works and polyethylene from Braskem. Thefibers may be or may comprise continuous fibers, such as spunbond fibersand melt-blown fibers. Carded staple fibers, either petroleum-sourced orbio-sourced, such as cotton, cellulous, and/or regenerated cellulous mayalso be included into the web and therefore are within the scope of themethods of the present disclosure. The multi-constituent fibers, such asbicomponent fibers, may comprise sheath/core, side-by-side, islands inthe sea, and/or eccentric configurations or may have otherconfigurations.

Using thinner fibers may help through-fluid bonding intermediatecontinuous fiber nonwoven webs to create softer continuous fibernonwoven webs. For example, the continuous fibers may have a decitex inthe range of about 0.5 to about 5, about 0.8 to about 4, about 0.8 toabout 3, about 0.8 to about 2, about 0.8 to about 1.5, about 1 to about1.4, about 1.1 to about 1.3, or about 1.2, specifically reciting all 0.1decitex increments within the specified ranges and all ranges formedtherein or thereby.

General Continuous Fiber Nonwoven Formation Process

Many nonwoven webs are made from melt-spinnable polymers and areproduced using a spunbond process. The term “spunbond” refers to aprocess of forming a nonwoven web from thin continuous fibers producedby extruding molten polymers from orifices of a spinneret. Thecontinuous fibers are drawn as they cool. Quenching of the continuousfibers may be performed by blowing air onto the continuous fibers fromone side or multiple sides under the spinneret in one or more open orenclosed chambers. Quench air temperate, flow rate, and humidity may becontrolled in one or more stages located along the continuous fibers.Continuous fiber speed may be in range from about 1000 m/min to about8000 m/min, for example, depending on the polymers selected. Air is themost common method of fiber attenuation in systems, such as mostlyenclosed chambers developed by Reifenhauser GmbH, or by aspiratorsdeveloped by Hills Inc., or inside Doncan systems developed by LurgiGmbH. Mechanical methods, such as take-up rollers, or electrostaticmethods may also be used for continuous fiber attenuation. Afterattenuation, the continuous fibers are randomly laid on a moving porousmember, such as a moving porous belt, such that the continuous fibersform an intermediate continuous fiber nonwoven web. The intermediatecontinuous fiber nonwoven web is subsequently bonded using one ofseveral known techniques, such as thermal point bonding or through-fluidbonding, for example, to form the nonwoven web. Spunbonding processes,however, result in low loft and softness in produced nonwoven webs dueto the heavy thermal point bonding and reduced ability for the fibers tocrimp on the moving porous member.

FIG. 1 diagrammatically illustrates an example apparatus 110 forproducing continuous fiber nonwoven webs. The apparatus 110 may comprisea hopper 112 into which pellets of a solid polymer may be placed. Thepolymer may be fed from the hopper 112 to a screw extruder 114 thatmelts the polymer pellets. The molten polymer may flow through a heatedpipe 116 to a metering pump 118 that in turn feeds the polymer stream toa suitable spin pack 120. The spin pack 120 may comprise a spinneret 122defining a plurality of orifices 124 that shape the fibers extrudedtherethrough. The orifices may be any suitable shape, such as round, forexample. If bi-component fibers are desired, another hopper 112′,another screw extruder 114′, another heated pipe 116′, and anothermetering pump 118′ may be included to feed a second polymer to thespinneret 122. The second polymer may be the same as or different thanthe first polymer. In some instances, the second polymer may be adifferent material and may have a different melting temperature as thefirst polymer as discussed herein. This difference in meltingtemperature allows formed bi-component fibers to crimp on the movingporous member as discussed herein. More than two polymer feed systemsmay also be included if 3 or more polymer components are desired.

Referring again to FIG. 1, an array of continuous fiber strands 126 mayexit the spinneret 122 of the spin pack 120 and may be pulled downwardby a drawing unit or aspirator 128, which may be fed by a fluid such ascompressed air or steam from a conduit or other fluid source 130.Specifically, the aspirator 128 uses fluid pressure or air pressure toform a fluid flow or air flow directed generally downward toward themoving porous member, which creates a downward fluid drag or air drag onthe continuous fibers, thereby increasing the velocity of the portion ofthe continuous fiber strands in and below the aspirator relative to thevelocity of the portion of the continuous fibers above the aspirator.The downward drawing of the continuous fibers longitudinally stretchesand transversely attenuates the continuous fiber strands. The aspirator128 may be, for example, of the gun type or of the slot type, extendingacross the full width of the continuous fiber array, i.e., in thedirection corresponding to a width of the intermediate nonwoven web tobe formed by the continuous fibers. The area between the spinneret 122and the aspirator 128 may be open to ambient air (open system) asillustrated or closed to ambient air (closed system).

The aspirator 128 delivers the attenuated continuous fibers 132 onto amoving porous member 134, such as a screen-type forming belt, which maybe supported and driven by rolls 136 and 138 or other mechanisms. Asuction box 140 may provide a negative fluid pressure to the movingporous member 134 and the intermediate continuous fiber nonwoven web onthe moving porous member 134. For example, the suction box 140 may beconnected to a fan to pull room air (at the ambient temperature) throughthe moving porous member 134, causing the continuous fibers 132 to forman intermediate continuous fiber nonwoven web 200 on the moving porousmember 134. The intermediate continuous fiber web 200 may pass throughan optional compaction roll 142 that applies a very light pressure(e.g., about 10 to about 60 psi, or less than 120 psi). In otherinstances, no compaction roll is used. The intermediate continuous fibernonwoven web 200 may then be conveyed on the moving porous member 134 orother conveyer or belt into a through-fluid bonding oven 144.

The through-fluid bonding oven 144 may take on various configurations,such as flat, omega shaped, stacked, single belt, or multiple belts, forexample. More than one though-fluid bonding oven may be used. Oneexample configuration is to have a hot fluid supply, such as hot air,above the web 200 and a hot fluid vacuum below the web 200. Of course,this configuration could be reversed to provide loft to the web in adirection opposite to the vacuum forces applied during continuous fiberlaydown. The hot fluid may be recycled in the through-fluid bonding oven144. The hot fluid may travel through the through-fluid bonding oven 144at a flow rate in the range of about 0.5 m/s to about 5 m/s and at atemperature in the range of about 10 degrees C. to about 280 degrees C.,for example. In some instances, it may be desirable to also have coolingwithin the through-fluid oven to set the fiber to fiber bonding.

If calendar bonding is not used, the intermediate continuous fibernonwoven webs 200 may have a tendency to blow-back in a directionopposite a direction of movement of the moving porous member 134. Thisfiber blow-back is not desired because it may create high basis weightareas and low basis weight areas or even holes in the intermediatenonwoven web 200. As such, it may be desirable to pre-bond (as in bondbefore through-fluid bonding) the intermediate nonwoven web 200 at alocation proximate to the suction box 140. The pre-bonding may providethe web with some structural integrity. The pre-bonding may be achievedby introducing a hot fluid, such as a hot air, infrared technology, orother technology, to the intermediate nonwoven web 200. As an example,the pre-bonding may occur via a short through-fluid bonding oven. Asanother example, the hot fluid may be provided by a fluid source 146positioned over the moving porous member and proximate to the suctionbox 136. The fluid source 146 may be a perforated plate or multiplefluid sources, for example, so that less than 100%, less than 75%, lessthan 50%, less than 25%, but greater than 10% of a surface of theintermediate nonwoven web 200 not facing the moving porous member 134receives pre-bonds. The pre-bonds may be intermittent in thecross-direction and/or the machine direction. It may be desirable topre-bond less than 100% or less of the surface of the intermediatenonwoven web 200 so that the surface is not sealed and the continuousfibers of the webs are still allowed to further entangle with eachother. The pre-bonds however, do help in preventing, or at leastinhibiting fiber blow-back and providing the web 200 with somestructural integrity.

In addition to pre-bonding, the intermediate nonwoven web 200 may bereentangled and/or reoriented prior to entering the through-fluidbonding oven 144. Reentangling and/or reorienting may occur by flowing afluid, such as air, from a fluid source 148 from under the moving porousmember 134 and into the intermediate nonwoven web 200. Reentanglingand/or reorienting the continuous fibers prior to through-fluid bondingmay help with loft, softness, and fiber entanglement of the intermediatenonwoven web 200.

The present disclosure provides methods for producing soft and loftythrough-fluid bonded continuous fiber nonwoven webs compared to typicalspunbond processes or even typical continuous fiber nonwoven webthrough-fluid bonded processes. As discussed herein, some factors toconsider in producing soft and lofty continuous fiber webs are: (1)allowing the continuous fibers to crimp once on a moving porous memberor belt; (2) inhibiting fiber blow-back on the moving porous member; (3)conveying the web on the moving porous member under reduced vacuumforces; and (4) conveying the web on the moving porous member at areduced machine directional strain, for example. The present disclosureprovides one or more methods of achieving these factors. It will beunderstood that some of the methods, or portions thereof, may be usedwith other of the methods, or portions thereof, to further optimize thewebs. For example, more than one process air diverter and/or remover maybe used with another process air diverter and/or remover.

Referring to FIG. 2, the process illustration of FIG. 1 is shown withprocess fluid handling, such as process fluid removal and/or diversion.The basic continuous fiber making process, other than the process fluidremoval and/or diversion, may be generally the same as explained hereinrelative to FIG. 1, including pre-bonding and fiber reentangling and/orreorienting, although not illustrated in FIG. 2. The continuous fibers132 meet the moving porous member 134 at a first location 202 and arethen conveyed downstream of the first location 202 toward thethrough-fluid bonding oven 144. It is noted that any of the “movingporous members” disclosed herein may have sections or portions that arenot porous, but at least some sections or portions of the moving porousmembers are able to have a fluid flow therethrough. These continuousfibers travel from the spinneret 122 in a process fluid, some of whichtravels with the intermediate continuous fiber web 200, downstream ofthe first location 202 and some of which is removed by the suction box140. It may be desirable to remove and/or divert at least some of theprocess fluid (e.g., air) that travels with the intermediate continuousfiber web 200 downstream of the first location 202. As such, a fluidremover or diverter may be useful especially in an absence of acompaction roll to reduce process fluids from interacting with stagnantfluids, thereby at least partially ruining web uniformity. Typically,the removal of the downstream process fluid has been accomplished byhaving vacuum under the moving porous member 200 downstream of the firstlocation which in turn draws the web 200 toward the moving porous memberand reduces fiber crimping and web loft and softness. Instead of suchremoval, or at least the same degree of removal, the present inventorshave invented more improved ways of removing and/or diverting processfluid while allowing the continuous fibers to crimp on the moving porousmember to achieve improved softness and loft.

Referring again to FIG. 2, a fluid handling roll 204 is providedproximate to, but downstream of, the first location 202. The fluidhandling roll 204 may rotate in the direction shown by the arrow and mayremove and blow-off fluid in different zones. At times, the blown-offfluid may be used to pre-bond the intermediate continuous fiber nonwovenweb as discussed further herein. In such an instances, the blown-offfluid may require heating. An elongated fluid diversion element 206 oran elongated fluid shield may be positioned over a portion of the movingporous member 134. The elongated fluid diversion element 206 may divertat least some process fluid from contact with the web 200 as the web 200moves downstream toward the through-fluid bonding oven 144. This mayreduce fiber blow-back. At times, the elongated fluid diversion element206 may actually contact a surface of the web in facing contact toitself, such that the web may be at least partially transported in themachine direction using shear forces between the moving porous member134 and the elongated fluid diversion element 206. This allows reductionof machine direction strain on the web 200, which also allows the web tofurther crimp and remain lofty as it is being conveyed toward thethrough-fluid bonding oven 144. The machine direction strain of the webintermediate the moving porous member 134 and the elongated fluiddiversion element 206 may be in the range of about −15% to about 5%,about −10% to about 5%, about −5% to about 5%, about −2% to about 5%,about −2% to about 3%, about −2% to about 1.8%, about −2% to about 1.5%,or about −2% to about 0.5%, for example. Machine direction strain may bedefined as the ((present length of the web minus original length of theweb at entry of the device where the web transport is assisted by shear,such as the fluid diversion element 204)/original length of theweb)×100%.

The elongated fluid diversion element 206 also allows for vacuum in thesuction box 140 and/or intermediate the suction box 140 and thethrough-fluid bonding oven 144 to be reduced or even eliminated. Thisalso promotes crimping of the fibers of the web 200. The elongated fluiddiversion element 206 may be adjustable in angle with respect to amachine direction of the web 200 or in a distance away from the movingporous member.

The elongated fluid diversion element 206 may be an elongated conveyoror an elongated plate. The elongated fluid diversion element 206 may begenerally fluid impermeable, but may have sections that are fluidpermeable. In the instance that it is desired that the elongated fluiddiversion element 206 contacts the web 200, the elongated conveyor or anelongated belt may be more suitable than the elongated plate. Theelongated conveyor or belt may move in the same direction as the movingporous member or a different or opposite direction as the moving porousmember, depending on the desired result. In any event, the elongatedfluid diversion element 206 may extend from the first location 202 tothe through-fluid bonding oven 144 or any distance therebetween. In someinstances, it may be desirable to have more than one elongated fluiddiversion element 206, such as two or three, for example. In such aninstance, the continuous fibers of the web 200 may be reoriented and/orrelofted intermediate the multiple elongated fluid diversion elements206. The elongated fluid diversion element 206 may be spaced a distancein the range of about 0.5 mm to about 20 mm, about 0.5 mm to about 15mm, or about 1 mm to about 10 mm, from the moving porous member 134,specifically reciting all 0.1 mm increments within the specified rangesand all ranges formed therein or thereby. This distance may beadjustable for different webs being produced. The elongated fluiddiversion element 206 may extend the full width of the intermediatecontinuous fiber nonwoven web 200, may extend greater than the fullwidth of the web 200, or may extend less than the full width of the web200. In some instances, more than one elongated fluid diversion elementmay be used in the cross machine direction and/or in the machinedirection. A heated fluid, such as heated air, may be passed through theelongated fluid diversion element 206 for pre-bonding of the web 200.

Referring to FIGS. 2-4, the elongated fluid diversion element 206 may beangled with respect to the moving porous member to reduce turbulence andensure smooth entry of the web 200 under the fluid diversion element206. The elongated fluid diversion element 206 may be angled in therange of about 40 degrees to about −40 degrees, about −30 degrees toabout 30 degrees, about −25 degrees to about 25 degrees, about −20degrees to about 20 degrees, about −15 degrees to about 15 degrees,about −10 degrees to about 10 degrees, about −5 degrees to about 5degrees, about −3 degrees to about 3 degrees, about −2 degrees to about2 degrees, about −1 degree to about 1 degree, or about −0.5 degrees toabout 0.5 degrees, relative to a machine direction of the moving porousmember 134, specifically reciting all 0.1 degree increments within thespecified ranges and all ranges formed therein or thereby. FIG. 3 showsan elongated fluid diversion element 206 that is an elongated conveyorand that has a negative angle relative to the machine direction (MD) ofthe moving porous member 134. FIG. 4 shows an elongated fluid diversionelement 206 that is an elongated conveyor and that has a positive anglerelative to the machine direction (MD) of the moving porous member 134.FIG. 5 illustrates an elongated fluid diversion element 206 that is anelongated plate and that is not angled with respect to the machinedirection (MD) of the moving porous member 134. The elongated plate maybe angled as discussed above. Further, the elongated conveyor may or maynot be angled. The elongated fluid diversion element 206 may be used inconjunction with the fluid handling roll 204, or process fluidremover/diverter (discussed below) or may be used without the fluidhandling roll 204 or the process fluid remover/diverter.

The elongated fluid diversion element 206 may be placed at a distance inthe range of about 0.1 meters to about 3 meters, or about 0.1 meters toabout 2 meters, for example, downstream in the machine direction from acenter of an impingement point (i.e., center of continuous fiber strandscontacting the moving porous member 134 in the first location 202). Suchdistance may depend on a machine direction width of the spinneret, butit may be desirable to place the elongated fluid diversion element 206as close to the fiber laydown stream (or first location) as possiblewithout creating disturbance of the fiber laydown.

Referring again to FIG. 4, a liquid and/or a moisturized fluid 208, suchas water or steam may be sprayed or applied to the intermediatecontinuous fiber nonwoven web 200 proximate to the first location 202 ordownstream of the first location 202. The liquid and/or moisturizedfluid 208 may be used to reduce fiber blow-back of the continuousfibers. This application of the liquid and/or moisturized fluid 2088 maybe used in conjunction with the fluid handling roll 204, the elongatedfluid diversion element 206, the process fluid remover/diverter, and/orother process fluid control equipment and methods of the presentdisclosure. The liquid and/or moisturized fluid 208 may also be used inconjunction with pre-bonding the web or may be used instead ofpre-bonding the web. The liquid and/or moisturized fluid 208, especiallywater or steam, will evaporate from the intermediate continuous fibernonwoven web 200 when the web is conveyed through the through-fluidbonding oven 144.

Referring to FIG. 6, a process fluid remover/diverter 210 may bepositioned proximate to the first location 202 or downstream of thefirst location. The process fluid remover/diverter 210 may be a plate,for example. The process fluid remover/diverter 210 may be used toprevent, or at least inhibit, process fluids from traveling downstreamwith the web 200, thereby reducing the need for a significant amountvacuum downstream to remove such process fluids. The process fluidremover/diverter 210 may be positioned proximate to an upper surface ofthe web 200 and extend upwardly a suitable distance, such as 10 or 12inches, for example. The process fluid remover/diverter 210 may extendfully across a width of the web or less than or greater than a width ofthe web. The process fluid remover/diverter 210 may optionally be usedin combination with an elongated fluid diversion element 206, such as anelongated conveyor, for example.

The fluid handling roll 204 and its various configurations will now bediscussed in greater detail. Referring to FIG. 7, the fluid handlingroll 204 may be positioned proximate to the first location 202 ordownstream of the first location. The roll 204 may have a vacuum zone212 and a blow-off zone 214. The vacuum zone 212 and the blow-off zone214 do not necessarily have to be 50% of the roll each. In an instance,the roll 204 may have more than one vacuum zone 212 and more than oneblow off zone 214. In other instances, the roll 204 may also have asingle vacuum zone and the process fluid may be removed from the rollvia a suction line, for example. Those of skill in the art willunderstand how to cycle vacuum and/or blow-off on and off. As an examplein FIG. 7, the vacuum zone 212 is shown with process fluid going intothe roll (by arrows) and the blow-off zone is shown with the processfluid going out of the roll (by arrows). The locations of the vacuumzone and the blow-off zone may stay the same as the roll rotates aboutits rotational axis 220. In such a fashion, the process fluid may beremoved from proximate to the first location 202 and blown-offdownstream of the first location 202 to reduce the need to remove asignificant amount of the process fluid by vacuum under the movingporous member downstream. This allows for better continuous fibercrimping and loft on the moving porous member 134. The fluid handlingroll 204 of FIG. 7 may optionally be used in combination with one ormore elongated fluid diversion elements 206, such as one or moreelongated conveyors, for example.

FIG. 8 illustrates another fluid handling roll 204. This fluid handlingroll 204 may be used to remove process fluid proximate to the firstlocation 202, use the removed process fluid to create fiber entanglementthat may function as pre-bonding in the intermediate continuous fibernonwoven webs 200 on the moving porous member 134, and optionally, ifprocess fluid is still available, blow-off the remainder of the processfluid. The pre-bonding would be a form of blowing-off the process fluid.This fluid may be heated prior to being blown-off. The fluid handlingroll 204, instead of removing process fluid, may merely intake ambientair, heat it, and then apply pre-bonds to the web 200. In otherinstances, a heated fluid may be provided to the fluid handling roll 204and the fluid handling roll 204 may apply pre-bonds to the web 200. Inthis instance, vacuum zones may not be provided. The fluid handling roll204 of FIG. 8 may optionally be used in combination with the fluiddiverter or remover or with one or more elongated fluid diversionelements 206, such as one or more elongated conveyors, for example.

FIG. 9 is an example front view of the fluid handling roll 204 of FIGS.7 and 8. The roll 204 may comprise an outer shell 216 and a plurality offluid ports 218 defined in the outer shell. The fluid ports 218 may bein any suitable pattern as long as they are configured to pre-bond lessthan 100%, less than 75% (or other ranges specified herein) of the web200. As the roll rotates about its rotational axis 220, positive and/ornegative fluid pressure may be provided to the fluid ports 218 dependingon which zone (vacuum/blow-off) those fluid ports are rotating through.In some instances, the roll 204 may only be used for blow-offpre-bonding when a heated fluid is supplied thereto.

The fluid ports 218 may be spaced a distance from each other in themachine direction (rotational direction of roll 204) and in thecross-machine direction. This allows blow-off that is intended forpre-bonding the web 200 to be intermittent in the machine direction andthe cross-machine direction. As discussed, it is desired to pre-bondless than 100%, less than 75%, less than 50%, less than 25%, but allgreater than 10% of the web 200. Pre-bonding less than an entire surfaceof the web 200 is desired to not lock or seal entire continuous fibersof the web and to provide the web with better air permeability so thatfiber crimping and reorientation may occur downstream of the pre-bondingoperation. Example pre-bonds 222 in a continuous fiber nonwoven web areillustrated in FIG. 10. The pre-bonds, however, may take on any suitableshape, pattern, configuration or density per unit area depending on thedesired pre-bonding.

The pre-bonds may also be created in the web 200 in other ways. In someinstances, the pre-bonds may be formed by a heated fluid that is not theprocess fluid, but instead is a separate heated fluid provided to theprocess. Referring to FIG. 11, the fluid 224 may be emitted from a fluidnozzle 226 toward a perforated plate 228 having a plurality of fluidports 230 or a perforated roll (like the roll illustrated in FIG. 9) toapply an intermittent or discontinuous pattern of pre-bonds to the web200. Other configurations of fluid application to the web in apre-bonding context are also within the scope of the present disclosure.The perforated plate and roll are just two examples. FIG. 12 illustratesa bottom view of the perforated plate 228 showing the plurality of fluidports 230. FIG. 13 is a cross-sectional view of the perforated plate ofFIG. 12, taken about line 13-13 of FIG. 12.

Any of the fluid handing roll 204, the fluid diverter 206, the processfluid remover/diverter 210, the perforated plate 228, and the water,steam, or other liquid being applied to the web may be used incombination. In some instances, less than all of the components or stepsmay be used together.

Methods

The methods of manufacturing soft and loft continuous fiber nonwovenwebs are now discussed. A method of manufacturing a soft and loftycontinuous fiber nonwoven web may comprise providing two or more moltenpolymer components having different melting temperatures to a spinneretdefining a plurality of orifices, and flowing a fluid, such as air,intermediate the spinneret and a moving porous member or moving porousbelt or screen. The moving porous member may be positioned below thespinneret. The bi-component continuous fiber strands may comprisepolyethylene and polypropylene or may comprise polyethylene andpolyethylene terephthalate. The different melting temperature of the twomolten polymer components may be at least 5 degrees, at least 10 degreesC., but all less than 180 degrees C., including other ranges specifiedherein. The method may comprise aspirating the continuous fiber strandsintermediate the spinneret and the moving porous member. Alternativelyto the aspirating, the method may comprise passing the continuous fiberstrands through a venturi intermediate the spinneret and the movingporous member. The method may comprise using the fluid to draw or pushthe two molten polymer components, in a direction that is toward themoving porous member, through at least some of the plurality of orificesto form a plurality of individual bi-component continuous fiber strands.The method may comprise depositing the continuous fiber strands on themoving porous member at a first location to produce an intermediatecontinuous fiber nonwoven web. The method may comprise first removingsome of the fluid under the first location. The method may comprisesecond removing and/or diverting some of the fluid proximate to, butdownstream of, the first location to maintain loft and softness in thedeposited intermediate continuous fiber nonwoven web.

The method may comprise blowing-off the removed fluid downstream of thefirst location. The blowing-off step may comprise pre-bonding portionsof the intermediate continuous fiber nonwoven web on the moving porousmember and downstream of the first location.

The method may comprise providing a fluid handling roll proximate to thefirst location to accomplish the second removing step and theblowing-off step. The fluid handling roll may comprise an outer shelland a plurality of fluid ports defined in the outer shell. The methodmay comprise rotating the fluid handling roll about a rotational axis.The fluid handling roll may comprise a vacuum zone proximate to thefirst location and a blow-off zone downstream of the first location.More than one vacuum zone and more than one blow-off zone may beprovided on a single fluid handling roll. The method may comprisecreating a negative fluid pressure in the fluid ports in the vacuum zoneto remove the fluid proximate to the first location and creating apositive fluid pressure in the fluid ports in the blow-off zone toblow-off the removed fluid downstream of the first location. The removedfluid may be used to intermittently pre-bond portions of theintermediate continuous fiber nonwoven web downstream of the firstlocation. The moving porous member may comprise a porous screen or mesh.The method may comprise creating a negative fluid pressure in the movingporous member.

The method may comprise providing a perforated roll or perforated platedownstream of the first location and proximate to the intermediatecontinuous fiber nonwoven web and flowing a heated fluid, such as heatedair, through the perforations to intermittently pre-bond portions of thecontinuous fibers of the intermediate continuous fiber nonwoven webtogether. The pre-bonds may be intermittent in a machine direction and across-machine direction.

The method may comprise third removing and/or diverting the fluid (i.e.,process fluid) from the intermediate continuous fiber nonwoven webdownstream of the first location. The method may comprise reducingvacuum forces applied to the intermediate continuous fiber nonwoven webduring the third removing and/or diverting step the fluid step. Thediverting step may comprise providing an elongated plate or an elongatedconveyor belt extending in a general direction of the moving porousmember, wherein the elongated plate or the elongated conveyer belt ispositioned over at least a portion of the moving porous member. Theelongated plate or the elongated conveyor may be angled with respect toa machine direction of the moving porous member in the range of about−40 degree to about 40 degrees, or other ranges specified herein. Theelongated plate or the elongated conveyor may be spaced a distance inthe range of 0.5 mm to about 15 mm, or other ranges specified herein,from the moving porous member. The method may comprise placing theelongated fluid diversion element a downstream machine directionaldistance in the range of about 0.1 to about 3 meters or about 0.1 metersto about 2 meters from a center of an impingement point (i.e., center ofcontinuous fiber strands contacting the moving porous member 134 in thefirst location 202). It may be desired to place the elongated fluiddiversion element as close to the fiber laydown stream or first locationas possible without creating a disturbance in the fiber laydown.

The method may comprise conveying the intermediate continuous fibernonwoven web through a through-fluid bonding oven to form a continuousfiber nonwoven web. The method may comprise reorienting the continuousfibers of the intermediate continuous fiber nonwoven web downstream ofthe first location. The method may comprise reorienting the continuousfibers of the intermediate continuous fiber nonwoven web downstream ofthe first location prior to the through-fluid bonding oven. The methodmay comprise allowing at least some of the continuous fibers of theintermediate continuous fiber nonwoven web to crimp on the moving porousmember downstream of the first location.

A method of creating a soft and lofty continuous fiber nonwoven web maycomprise providing two molten polymer components having differentmelting temperatures to a spinneret defining a plurality of orifices andflowing a fluid, such as air, intermediate the spinneret and a movingporous member. The moving porous member may be positioned below thespinneret. The method may comprise using the fluid to draw or push thetwo molten polymer components, in a direction that is toward the movingporous member, through at least some of the plurality of orifices toform a plurality of individual bi-component continuous fiber strands.The method may comprise depositing the continuous fiber strands on themoving porous member at a first location to form an intermediatecontinuous fiber nonwoven web, first removing some of the fluid underthe first location, second removing and/or diverting some of the fluidproximate to, but downstream of, the first location to maintain loft andsoftness in the deposited intermediate continuous fiber nonwoven web,and pre-bonding less than 75%, or other ranges specified herein, of anon-porous moving member surface of the intermediate continuous fibernonwoven web downstream of the first location.

The method may comprise allowing the continuous fibers of theintermediate fiber nonwoven web to crimp on the moving porous memberdownstream of the first location. The method may comprise third removingand/or diverting the fluid from the intermediate continuous fibernonwoven web downstream of the first location. The method may comprisethrough-fluid bonding the intermediate continuous fiber nonwoven web toform a continuous fiber nonwoven web.

A method of creating a soft and lofty continuous fiber nonwoven web maycomprise providing two molten polymer components having differentmelting temperatures to a spinneret defining a plurality of orifices andflowing a fluid intermediate the spinneret and a moving porous member.The moving porous member may be positioned below the spinneret. Themethod may comprise using the fluid to draw or push the two moltenpolymer components, in a direction that is toward the moving porousmember, through at least some of the plurality of orifices to form aplurality of individual bi-component continuous fiber strands. Themethod may comprise depositing the continuous fiber strands on themoving porous member at a first location to form an intermediatecontinuous fiber nonwoven web, and pre-bonding less than 100%, or otherranges specified herein, of a non-porous moving member surface of theintermediate continuous fiber nonwoven web downstream of the firstlocation. The method may comprise through-fluid bonding the intermediatecontinuous fiber nonwoven web to form a continuous fiber nonwoven web.

A method of creating a soft and lofty continuous fiber nonwoven web maycomprise providing two molten polymer components having differentmelting temperatures to a spinneret defining a plurality of orifices andflowing a fluid intermediate the spinneret and a moving porous member.The moving porous member is positioned below the spinneret. The methodmay comprise using the fluid, mechanical mechanisms, or electrostaticmechanisms to draw or push the two molten polymer components, in adirection that is toward the moving porous member, through at least someof the plurality of orifices to form a plurality of individualbi-component continuous fiber strands. The method may comprisedepositing the continuous fiber strands on the moving porous member at afirst location to form an intermediate continuous fiber nonwoven web andapplying a liquid and/or moisturized fluid 208 to a non-porous movingmember surface of the intermediate continuous fiber nonwoven webdownstream of the first location to reduce continuous fiber blow back.The method may comprise first removing some of the fluid under the firstlocation, and second removing and/or diverting some of the fluidproximate to, but downstream of, the first location to maintain loft andsoftness in the deposited intermediate continuous fiber nonwoven web.The method may comprise third removing and/or diverting the fluid fromthe intermediate continuous fiber nonwoven web downstream of the firstlocation. The method may comprise through-fluid bonding the intermediatecontinuous fiber nonwoven web to form a continuous fiber nonwoven web.

Examples/Combinations

A. A method of creating a soft and lofty continuous fiber nonwoven web,the method comprising:

providing two molten polymer components having different meltingtemperatures to a spinneret defining a plurality of orifices;

flowing a fluid intermediate the spinneret and a moving porous member,wherein the moving porous member is positioned below the spinneret;

using the fluid to draw or push the two molten polymer components, in adirection that is toward the moving porous member, through at least someof the plurality of orifices to form a plurality of individualbi-component continuous fiber strands;

depositing the continuous fiber strands on the moving porous member at afirst location to form an intermediate continuous fiber nonwoven web;

first removing some of the fluid under the first location;

second removing and/or diverting some of the fluid proximate to, butdownstream of, the first location to maintain loft and softness in thedeposited intermediate continuous fiber nonwoven web; and

pre-bonding less than 75% of a non-porous moving member surface of theintermediate continuous fiber nonwoven web downstream of the firstlocation.

B. The method of Paragraph A, comprising allowing the continuous fibersof the intermediate fiber nonwoven web to crimp on the moving porousmember downstream of the first location.

C. The method of Paragraph A or B, comprising third removing and/ordiverting the fluid from the intermediate continuous fiber nonwoven webdownstream of the first location.

D. The method of any one of Paragraphs A-C, comprising through-fluidbonding the intermediate continuous fiber nonwoven web to form acontinuous fiber nonwoven web.

E. A method of creating a soft and lofty continuous fiber nonwoven web,the method comprising:

providing two molten polymer components having different meltingtemperatures to a spinneret defining a plurality of orifices;

flowing a fluid intermediate the spinneret and a moving porous member,wherein the moving porous member is positioned below the spinneret;

using the fluid to draw or push the two molten polymer components, in adirection that is toward the moving porous member, through at least someof the plurality of orifices to form a plurality of individualbi-component continuous fiber strands;

depositing the continuous fiber strands on the moving porous member at afirst location to form an intermediate continuous fiber nonwoven web;

pre-bonding less than 100% of a non-porous moving member surface of theintermediate continuous fiber nonwoven web downstream of the firstlocation.

F. The method of Paragraph E, comprising through-fluid bonding theintermediate continuous fiber nonwoven web to form a continuous fibernonwoven web.

G. A method of creating a soft and lofty continuous fiber nonwoven web,the method comprising:

providing two molten polymer components having different meltingtemperatures to a spinneret defining a plurality of orifices;

flowing a fluid intermediate the spinneret and a moving porous member,wherein the moving porous member is positioned below the spinneret;

using the fluid to draw or push the two molten polymer components, in adirection that is toward the moving porous member, through at least someof the plurality of orifices to form a plurality of individualbi-component continuous fiber strands;

depositing the continuous fiber strands on the moving porous member at afirst location to form an intermediate continuous fiber nonwoven web;

applying a liquid or moisturized fluid to a non-porous moving membersurface of the intermediate continuous fiber nonwoven web downstream ofthe first location.

H. The method of Paragraph G, comprising:

first removing some of the fluid under the first location; and

second removing and/or diverting some of the fluid proximate to thefirst location to maintain loft and softness in the depositedintermediate continuous fiber nonwoven web.

I. The method of Paragraph H, comprising third removing and/or divertingthe fluid from the intermediate continuous fiber nonwoven web downstreamof the first location.

J. The method of any one of Paragraphs G-I, comprising through-fluidbonding the intermediate continuous fiber nonwoven web to form acontinuous fiber nonwoven web.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany embodiment disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such embodiment. Further, to the extent that any meaningor definition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications may be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. A method of manufacturing a soft and loftycontinuous fiber nonwoven web, the method comprising: providing twomolten polymer components having different melting temperatures to aspinneret defining a plurality of orifices; flowing a fluid intermediatethe spinneret and a moving porous member, wherein the moving porousmember is positioned below the spinneret; using the fluid to draw orpush the two molten polymer components, in a direction that is towardthe moving porous member, through at least some of the plurality oforifices to form a plurality of individual bi-component continuous fiberstrands; depositing the continuous fiber strands on the moving porousmember at a first location to produce an intermediate continuous fibernonwoven web; first removing some of the fluid under the first location;second removing and/or diverting some of the fluid proximate to, butdownstream of, the first location to maintain loft and softness in thedeposited intermediate continuous fiber nonwoven web; and reorientingthe continuous fibers of the intermediate continuous fiber nonwoven webdownstream of the first location.
 2. The method of claim 1, comprisingblowing-off the second removed fluid downstream of the first location.3. The method of claim 2, wherein the blowing-off step comprises heatingthe fluid and pre-bonding portions of the intermediate continuous fibernonwoven web on the moving porous member and downstream of the firstlocation.
 4. The method of claim 2, comprising: providing a fluidhandling roll proximate to the first location to accomplish the removingstep and the blowing-off step, the fluid handling roll comprising: anouter shell; and a plurality of fluid ports defined in the outer shell;rotating the fluid handling roll about a rotational axis; wherein thefluid handling roll comprises a vacuum zone proximate to the firstlocation and a blow-off zone downstream of the first location; creatinga negative fluid pressure in the fluid ports in the vacuum zone toremove the fluid proximate to the first location; and creating apositive fluid pressure in the fluid ports in the blow-off zone toblow-off the removed fluid downstream of the first location.
 5. Themethod of claim 4, wherein the second removed fluid is used tointermittently pre-bond portions of the intermediate continuous fibernonwoven web downstream of the first location.
 6. The method of claim 1,wherein the moving porous member comprises a porous screen or mesh, themethod comprising creating a negative fluid pressure in the movingporous member.
 7. The method of claim 1, comprising: providing aperforated roll or perforated plate downstream of the first location andproximate to the intermediate continuous fiber nonwoven web; and flowinga heated fluid through the perforations to intermittently pre-bondportions of the continuous fibers of the intermediate continuous fibernonwoven web together.
 8. The method of claim 7, wherein the pre-bondsare intermittent in a machine direction and a cross-machine direction.9. The method of claim 1, comprising: third removing and/or divertingthe fluid from the intermediate continuous fiber nonwoven web downstreamof the first location to shield the intermediate continuous fibernonwoven web from surrounding fluids.
 10. The method of claim 9,comprising: reducing vacuum forces applied to the intermediatecontinuous fiber nonwoven web during the third removing and/or divertingstep.
 11. The method of claim 9, wherein the diverting step comprisesproviding an elongated plate or an elongated conveyor extending in ageneral direction of the moving porous member, and wherein the elongatedplate or the elongated conveyer is positioned over at least a portion ofthe moving porous member.
 12. The method of claim 11, wherein theelongated plate or the elongated conveyor is angled with respect to amachine direction of the moving porous member in the range of about −40degree to about 40 degrees, and wherein the elongated plate or theelongated conveyor is spaced a distance in the range of 0.5 mm to about15 mm from the moving porous member.
 13. The method of claim 1,comprising conveying the intermediate continuous fiber nonwoven webthrough a through-fluid bonding oven to form a continuous fiber nonwovenweb.
 14. The method of claim 1, comprising allowing at least some of thecontinuous fibers of the intermediate continuous fiber nonwoven web tocrimp on the moving porous member downstream of the first location. 15.The method of claim 1, wherein the bi-component continuous fiber strandscomprise polyethylene and polypropylene, or wherein the bi-componentcontinuous fiber strands comprise polyethylene and polyethyleneterephthalate.
 16. The method of claim 1, wherein the different meltingtemperature of the two molten polymer components is at least 10 degreesC., at least 20 degrees C., or at least 30 degrees C., but less than 180degrees C.
 17. The method of claim 1, comprising aspirating thecontinuous fiber strands intermediate the spinneret and the movingporous member.
 18. The method of claim 1, comprising passing thecontinuous fiber strands through a venturi intermediate the spinneretand the moving porous member.
 19. The method of claim 1, comprisingusing a roller to mechanically stretch the continuous fiber strandsintermediate the spinneret and the moving porous member.
 20. The methodof claim 1, wherein the moving porous member comprises at least oneportion that is non-porous.
 21. The method of claim 1, comprisingpre-bonding less than 75% of a non-porous moving member surface of theintermediate continuous fiber nonwoven web downstream of the firstlocation.
 22. A method of creating a soft and lofty continuous fibernonwoven web, the method comprising: providing two molten polymercomponents having different melting temperatures to a spinneret defininga plurality of orifices; flowing a fluid intermediate the spinneret anda moving porous member, wherein the moving porous member is positionedbelow the spinneret; using the fluid to draw or push the two moltenpolymer components, in a direction that is toward the moving porousmember, through at least some of the plurality of orifices to form aplurality of individual bi-component continuous fiber strands;depositing the continuous fiber strands on the moving porous member at afirst location to form an intermediate continuous fiber nonwoven web;first removing some of the fluid under the first location; secondremoving and/or diverting some of the fluid proximate to, but downstreamof, the first location to maintain loft and softness in the depositedintermediate continuous fiber nonwoven web; pre-bonding less than 75% ofa non-porous moving member surface of the intermediate continuous fibernonwoven web downstream of the first location; and reorienting thecontinuous fibers of the intermediate continuous fiber nonwoven webdownstream of the first location.
 23. A method of manufacturing a softand lofty continuous fiber nonwoven web, the method comprising:providing two molten polymer components having different meltingtemperatures to a spinneret defining a plurality of orifices; flowing afluid intermediate the spinneret and a moving porous member, wherein themoving porous member is positioned below the spinneret; using the fluidto draw or push the two molten polymer components, in a direction thatis toward the moving porous member, through at least some of theplurality of orifices to form a plurality of individual bi-componentcontinuous fiber strands; depositing the continuous fiber strands on themoving porous member at a first location to produce an intermediatecontinuous fiber nonwoven web; first removing some of the fluid underthe first location; second removing and/or diverting some of the fluidproximate to, but downstream of, the first location to maintain loft andsoftness in the deposited intermediate continuous fiber nonwoven web;providing a perforated roll or perforated plate downstream of the firstlocation and proximate to the intermediate continuous fiber nonwovenweb; and flowing a heated fluid through the perforations tointermittently pre-bond portions of the continuous fibers of theintermediate continuous fiber nonwoven web together.